Radio Control Equipment Instruction Manual - Magnetek/media/Manuals/Material Handling...

Flex 12EX-A/B System Radio Control Equipment

Instruction Manual

0-FLEX-12EXABME R4 December 2013

© Copyright 2013 Magnetek Material Handling

Flex 12EX A/B System Instruction Manual December 2013

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Service Information

Your New Radio System Thank you for your purchase of Magnetek’s Enrange™ Flex EX radio remote control system. Without a doubt, our Flex EX system is the ultimate solution for providing precise, undeterred, and safe control of your material. If your product ever needs modification or service, please contact one of our representatives at the following locations: U.S. Service Information For questions regarding service or technical information contact: +1.866.MAG.SERV +1.866.624.7378 World Headquarters: Magnetek, Inc. N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Telephone: +1.800.288.8178 Website: www.magnetek.com e-mail: [email protected] Fax Numbers: Main: +1.800.298.3503 Sales: +1.262.783.3510 Service: +1.262.783.3508 Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetek.com. ©2013 MAGNETEK All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of MAGNETEK.


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PRODUCT MANUAL SAFETY INFORMATION Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know, understand and follow the instructions and safety recommendations in this manual for Magnetek Products. The recommendations in this manual do not take precedence over any of the following requirements relating to cranes, hoists lifting devices or other material handling equipment which use or include Magnetek Products:

Instructions, manuals, and safety warnings of the manufacturers of the equipment where the radio system is used,

Plant safety rules and procedures of the employers and the owners of facilities where the Magnetek Products are being used,

Regulations issued by the Occupational Health and Safety Administration (OSHA), Applicable local, state or federal codes, ordinances, standards and requirements, or Safety standards and practices for the industries in which Magnetek Products are used.

This manual does not include or address the specific instructions and safety warnings of these manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the responsibility of the employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained. No one should use Magnetek Products prior to becoming familiar with and being trained in these requirements and the instructions and safety recommendations in this manual.

WARRANTY INFORMATION For information on Magnetek’s product warranties by product type, please visit www.magnetek.com.


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Table of Contents 1. INTRODUCTION ....................................................................................................................................... 6 2. RADIO CONTROLLED SAFETY .............................................................................................................. 7

2.1 CRITICAL INSTALLATION CONSIDERATIONS ................................................................................ 8 2.2 GENERAL ........................................................................................................................................... 8 2.3 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES .................................... 8 2.4 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS ..................................................................................................................... 9 2.5 TRANSMITTER UNIT........................................................................................................................ 10 2.6 PRE-OPERATION TEST .................................................................................................................. 10 2.7 BATTERIES ....................................................................................................................................... 11 2.8 BATTERY HANDLING ...................................................................................................................... 11 2.9 BATTERY CHARGING...................................................................................................................... 11 2.10 BATTERY DISPOSAL ..................................................................................................................... 11 2.11 SPECIFIC SYSTEM WARNINGS ................................................................................................... 12

3. GENERAL SYSTEM INFORMATION ..................................................................................................... 13 3.1 TRANSMITTER HANDSET ............................................................................................................... 13

3.1.1 External Illustration (Standard Push Button Configuration) ........................................................ 13 3.1.2 Internal Illustration....................................................................................................................... 14

3.2 RECEVIER UNIT ............................................................................................................................... 15 3.2.1 External Illustration ..................................................................................................................... 15 3.2.2 Internal Illustration....................................................................................................................... 16

4. FUNCTION SETTINGS ........................................................................................................................... 17 4.1 TRANSMITTER HANDSET ............................................................................................................... 17

4.1.1 System Channel Settings ........................................................................................................... 17 4.1.2 Continuous Transmitting Time Adjustment ................................................................................. 18 4.1.3 Push Button Functions with LED Displays ................................................................................. 19

4.1.3.1 Standard Push Button Configuration (Transmitter Toggle) .................................................. 19 4.1.3.2 Standard Push Button Configuration (A/B Selector) ............................................................ 20 4.1.3.3 Inline Push Button Configuration (Transmitter Toggle) ........................................................ 22 4.1.3.4 Inline Push Button Configuration (A/B Selector) .................................................................. 23

4.1.4 Channel Change via Push Buttons ............................................................................................. 26 4.1.5 Optional 4-Digit Security Code ................................................................................................... 27 4.1.6 I-CHIP ......................................................................................................................................... 28

4.2 RECEIVER UNIT ............................................................................................................................... 29 4.2.1 System Channel Settings ........................................................................................................... 29 4.2.2 Output Relay Configurations ....................................................................................................... 30

4.2.2.1 Output Relay Types ............................................................................................................. 30 4.2.2.2 Output Relay Actions at 2nd Speed ..................................................................................... 30 4.2.2.3 ON/OFF Push Button Function ............................................................................................ 31 4.2.2.4 START/AUX Function .......................................................................................................... 31 4.2.2.5 Magnet ON/OFF Push Button Function ............................................................................... 32 4.2.2.6 Brake Function ..................................................................................................................... 32 4.2.2.7 Momentary Contact .............................................................................................................. 32 4.2.2.8 Toggled Contact ................................................................................................................... 32 4.2.2.9 3rd Speed Push Button Function ......................................................................................... 32 4.2.2.10 Auxiliary STOP Push Button Function ............................................................................... 32 4.2.2.11 Pitch & Catch Function ....................................................................................................... 32

4.2.3 Receiver Auto-Scanning Settings ............................................................................................... 33 4.2.4 Dip-Switch Settings ..................................................................................................................... 34

4.2.4.1 Interlocked Functions ........................................................................................................... 34 4.2.4.2 Non-Interlocked Functions ................................................................................................... 35

4.2.5 Jumper Settings .......................................................................................................................... 36 4.2.6 I-CHIP Programming Port ........................................................................................................... 37 4.2.7 Voltage Settings .......................................................................................................................... 37


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5. SYSTEM CHANNELS TABLE ................................................................................................................ 38 6. RECEIVER INSTALLATION ................................................................................................................... 39

6.1 OUTPUT RELAY CONTACT DIAGRAM ........................................................................................... 39 6.2 PRE-INSTALLATION PRECAUTIONS ............................................................................................. 40 6.3 STEP-BY-STEP INSTALLATION ...................................................................................................... 40 6.4 SYSTEM TESTING ........................................................................................................................... 41

7. Operating Procedure ............................................................................................................................... 42 7.1 TRANSMITTER OPERATION ........................................................................................................... 42

7.1.1 General Operating Procedure ..................................................................................................... 42 7.1.2 Rotary Select A/B Operating Procedure ..................................................................................... 43 7.1.3 Push Button Select A/B Operating Procedure ............................................................................ 43 7.1.4 3rd Speed Push Button Operating Procedure ............................................................................ 44 7.1.5 Pitch & Catch Operating Procedure ............................................................................................ 44 7.1.6 Automatic Channel Scanning Operating Procedure ................................................................... 44 7.1.7 Changing Transmitter Batteries .................................................................................................. 45

7.2 STATUS LIGHT INDICATORS & WARNINGS ................................................................................. 46 7.2.1 Transmitter STATUS Light Indication ......................................................................................... 46 7.2.2 Receiver STATUS Light Indication ............................................................................................. 47 7.2.3 Receiver SQ Light Indication ...................................................................................................... 47 7.2.4 Receiver POWER Light Indication .............................................................................................. 47 7.2.5 Receiver COM Light Indication ................................................................................................... 47

7.3 TROUBLESHOOTING TIPS ............................................................................................................. 48 8. SYSTEM SPECIFICATIONS .................................................................................................................. 49


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1. INTRODUCTION The Flex radio remote control systems are designed for control of industrial equipment and machinery such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches, monorails, conveyor belts, mining equipment and other material handling equipment where wireless control is preferred. Each Flex system consists of a transmitter handset and receiver unit. Other standard-equipped accessories include transmitter waist belt, spare transmitter power key, clear vinyl pouch, “AA” alkaline batteries, compass direction decal sheet and user’s manual. List of notable features include:

62 user-programmable channels – Advanced synthesized RF controls with 62 built-in channels; there are no more fixed channels and fragile quartz crystals to break.

Automatic channel scanning receiver – No more hassle of climbing up the crane to change

receiver channels.

Over one million unique ID codes (20bit) – Each and every Flex system has its own unique ID codes and serial number; never repeats.

Advanced controls – The Flex system utilizes advanced microprocessor controls with 32bit

CRC and Hamming Code, which provide ultra-fast, safe, precise, and error-free encoding and decoding.

Unique I-CHIP design – The I-CHIP functions in a way that is very similar to SIM cards used on

mobile phones, with the ability to transfer system information and settings from one transmitter to another without the hassle of resetting the spares.

Reliable push buttons – The in-house designed push buttons with gold-plated contacts are

rated for more than one million press cycles.

Low power consumption – Requires only two “AA” Alkaline batteries for more than 100 hours of operating time between replacements.

Ultra-durable nylon and fiberglass composite enclosures – Highly resistant to breakage and

deformation even in the most abusive environments.

Full compliance – All systems are fully compliant with the FCC Part-15 Rules, European Directives (Safety, EMC, R&TTE, Machinery), and Industry Canada Specifications (IC).


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2. RADIO CONTROLLED SAFETY WARNINGS and CAUTIONS Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight items critical to the protection of personnel and equipment. WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in injury or death of personnel, or long term physical hazards. Warnings are highlighted as shown below:

WARNING

CAUTION – A caution highlights an essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in damage to, or destruction of equipment, or loss of functional effectiveness. Cautions are highlighted as shown below:

CAUTION

WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED. The safety rules in this section are not intended to replace any rules or regulations of any applicable local, state, or federal governing organizations. Always follow your local lockout and tagout procedure when maintaining any radio equipment. The following information is intended to be used in conjunction with other rules or regulations already in existence. It is important to read all of the safety information contained in this section before installing or operating the Radio Control System.


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2.1 CRITICAL INSTALLATION CONSIDERATIONS

WARNING PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOP AN UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES, HOISTS, LIFTING DEVICES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD. THESE AUDIBLE AND/OR VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE, HOIST, LIFTING DEVICE OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES. DE-ENERGIZE AND TAGOUT ALL SOURCES OF ELECTRICAL POWER BEFORE TOUCH-TESTING ANY EQUIPMENT. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE SAFETY CRITICAL MAINTAINED FUNCTIONS, I.E., MAGNETS, VACUUM LIFTS, PUMPS, EMERGENCY EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER CONSIDERATIONS MUST BE PROVIDED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH OR DAMAGE TO EQUIPMENT.

2.2 GENERAL Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices and other material handling equipment can be large, and operate at high speeds. Quite frequently, the equipment is operated in areas where people are working in close proximity to the material handling equipment. The operator must exercise extreme caution at all times. Workers must constantly be alert to avoid accidents. The following recommendations have been included to indicate how careful and thoughtful actions may prevent injuries, damage to equipment, or even save a life.

2.3 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES Only properly trained persons designated by management should be permitted to operate radio controlled equipment. Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be operated by any person who cannot read or understand signs, notices and operating instructions that pertain to the equipment. Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by any person who may be suffering from a disorder or illness, is taking any medication that may cause loss of equipment control, or is under the influence of alcohol or drugs.


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2.4 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment. The operator should:

have knowledge of hazards pertaining to equipment operation

have knowledge of safety rules for radio controlled equipment

have the ability to judge distance of moving objects

know how to properly test prior to operation

be trained in the safe operation of the radio transmitter as it pertains to the crane, hoist, lifting device or other material handling equipment being operated

have knowledge of the use of equipment warning lights and alarms

have knowledge of the proper storage space for a radio control transmitter when not in use be trained in transferring a radio control transmitter to another person

be trained how and when to report unsafe or unusual operating conditions

test the transmitter emergency stop and all warning devices prior to operation; testing should be done on

each shift, without a load

be thoroughly trained and knowledgeable in proper and safe operation of the crane, hoist, lifting device, or other material handling equipment that utilizes the radio control

know how to keep the operator and other people clear of lifted loads and to avoid “pinch” points

continuously watch and monitor status of lifted loads

know and follow cable and hook inspection procedures

know and follow the local lockout and tagout procedures when servicing radio controlled equipment

know and follow all applicable operating and maintenance manuals, safety procedures, regulatory

requirements, and industry standards and codes The operator shall not:

lift or move more than the rated load

operate the material handling equipment if the direction of travel or function engaged does not agree with what is indicated on the controller

use the crane, hoist or lifting device to lift, support or transport people

lift or carry any loads over people

operate the crane, hoist or lifting device unless all persons, including the operator, are and remain clear of

the supported load and any potential pinch points

operate a crane, hoist or lifting device when the device is not centered over the load

operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the sprockets, drum or sheave


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operate any damaged or malfunctioning crane, hoist, lifting device or other material handling equipment

change any settings or controls without authorization and proper training

remove or obscure any warning or safety labels or tags

leave any load unattended while lifted

leave power on the radio controlled equipment when the equipment is not in operation

operate any material handling equipment using a damaged controller because the unit may be unsafe

operate manual motions with other than manual power

operate radio controlled equipment when low battery indicator is on

WARNING THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

2.5 TRANSMITTER UNIT Transmitter switches should never be mechanically blocked ON or OFF. When not in use, the operator should turn the transmitter OFF. A secure storage space should be provided for the transmitter unit, and the transmitter unit should always be placed there when not in use. This precaution will help prevent unauthorized people from operating the material handling equipment. Spare transmitters should be stored in a secure storage space and only removed from the storage space after the current transmitter in use has been turned OFF, taken out of the service area and secured.

2.6 PRE-OPERATION TEST At the start of each work shift, or when a new operator takes control of the crane, operators should do, as a minimum, the following steps before making lifts with any crane or hoist: Test all warning devices. Test all direction and speed controls. Test the transmitter emergency stop.


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2.7 BATTERIES

WARNING KNOW AND FOLLOW PROPER BATTERY HANDLING, CHARGING AND DISPOSAL PROCEDURES. IMPROPER BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

2.8 BATTERY HANDLING Use only batteries approved by Magnetek for the specific product. Do not dispose of a battery pack in fire; it may explode. Do not attempt to open the battery pack. Do not short circuit the battery. For intrinsically safe environments only use specified Magnetek Telemotive intrinsically safe batteries. Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight or close to a heating source).

2.9 BATTERY CHARGING For those transmitters equipped with battery chargers, please familiarize all users with the instructions of the charger before attempting to use. Do not attempt to charge non-rechargeable battery packs. Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life. Avoid charging the battery pack for more than 24 hours at a time. Do not charge batteries in a hazardous environment. Do not short the charger. Do not attempt to charge a damaged battery. Use only Magnetek Telemotive approved chargers for the appropriate battery pack. Do not attempt to use a battery that is leaking, swollen or corroded. Charger units are not intended for outdoor use. Use only indoors.

2.10 BATTERY DISPOSAL Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure.


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2.11 SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex 12EX-A/B System:

1. Check the Status LED on the transmitter for any signs of low battery power (refer to page 46).

2. Check the Status LED on the transmitter for any signs of irregularities (refer to page 46).

3. Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters (900 feet).

4. Never operate a crane or equipment with two transmitter handsets at the same time unless they

are programmed with the “Pitch & Catch” function. For information on the “Pitch & Catch” feature, please refer to page 32 and page 44 of this manual.


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3. GENERAL SYSTEM INFORMATION

3.1 TRANSMITTER HANDSET

3.1.1 External Illustration (Standard Push Button Configuration)

(Fig. 01) (Fig. 02) 1. Emergency Stop Button 8. Select A/B/A+B switch 15. Strap Ring 2. Removable Power Key Switch 9. Push Button #1 16. System Information 3. Push Button #2 10. Push Button #3 17. System Channel 4. Push Button #4 11. Push Button #5 18. Crane Number 5. Push Button #6 12. Push Button #7 19. Battery Cover 6. Push Button #8 13. Push Button #9 20. Approval Info 7. Push Button #10 14. Push Button #11


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3.1.2 Internal Illustration

(Fig. 03) (Fig. 04)

1. Encoder Board 6. I-CHIP 2. Arial Antenna 7. Function Dip-Switch 3. Transmitting Module 8. Channel Dip-Switch 4. Status LED Display 9. Battery Contact Mechanism

5. Function LED Displays


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3.2 RECEVIER UNIT

3.2.1 External Illustration

(Fig. 05)

1. Shock Mount 6. COM LED Display 2. External Antenna Jack 7. Output Contact Diagram 3. Power LED Display 8. System Information 4. Status LED Display 9. Cord Grip 5. SQ LED Display


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3.2.2 Internal Illustration

(Fig. 06)

1. AC Line Filter 4. Decoder Module 2. Power Transformer 5. Output Relay Board 3. Receiving Module


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4. FUNCTION SETTINGS 4.1 TRANSMITTER HANDSET

4.1.1 System Channel Settings

(Fig. 07) Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Fig. 07 above). Only the first six (6) positions are used for channel programming (refer to Fig. 08 below). The system channels table located on page 38 illustrates which dip-switch setting corresponds to which channel. Once the transmitter channel is altered, make sure to change the receiver channel as well. The channel on both the transmitter and receiver must be identical in order for the system to work. To change the receiver channel please refer to page 29. Example:

(Fig. 08)

The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38.


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4.1.2 Continuous Transmitting Time Adjustment

After the push button is released the transmitter will continue to transmit neutral signals to the receiver for up to one (1) minute. After one (1) minute the transmitter will cease transmission thus temporarily disconnecting the receiver MAIN.

After the push button is released the transmitter will continue to transmit neutral signals to the receiver for up to three (3) minutes. After three (3) minutes the transmitter will cease transmission thus temporarily disconnecting the receiver MAIN. Please contact your local dealer if your application requires transmitting on time other than the pre-set value above.


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4.1.3 Push Button Functions with LED Displays

4.1.3.1 Standard Push Button Configuration (Transmitter Toggle) Set the transmitter toggle (latching output relay) function by adjusting the 8-position function dip-switch located on the backside of the transmitter encoder board (refer to Fig. 09 below). The LED 1 through LED 4 shown inside the shaded box (see below) illustrates which LED on the transmitter will light up when the designated push button (PB7 - PB11) is pressed.

(Fig. 09)

DIP PB7 PB8 PB9 PB10 PB11

1 00000000 Normal Normal Normal Normal Normal

2 00001001 Normal Normal Normal LED 4 Normal

3 00001010 Normal Normal LED 3 LED 4 Normal

4 00001011 Normal LED 2 LED 3 LED 4 Normal

5 00001100 LED 1 LED 2 LED 3 LED 4 Normal


7 00001110 Normal Normal Normal Normal LED 3

8 00001111 Normal Normal Normal LED 2 LED 3

9 00010000 Normal Normal LED 1 LED 2 LED 3

* PB7…PB11 → Push button number * Normal → Normal momentary contact * LED 1…LED 4 → Transmitter toggled with designated LED Display


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4.1.3.2 Standard Push Button Configuration (A/B Selector)

There are four (4) different types of A/B selector sequences available on the Flex system. Choose the one that is most suitable for your application. Type-A selector sequence : A+B → A → B → A+B … Type-B selector sequence : Off → A → B → Off → A → B … Type-C selector sequence : A → B → A+B → A → B → A+B … Type-D selector sequence : Off → A → B → A+B → Off → A → B → A+B …


10 00101111 A/1&2 Normal Normal Normal Normal

11 00110000 B/1&2 Normal Normal Normal Normal

12 00110001 C/1&2 Normal Normal Normal Normal

13 00110010 D/1&2 Normal Normal Normal Normal

14 00110011 Normal A/3&4 Normal Normal Normal

15 00110100 Normal B/3&4 Normal Normal Normal

16 00110101 Normal C/3&4 Normal Normal Normal

17 00110110 Normal D/3&4 Normal Normal Normal

18 00110111 A/1&2 A/3&4 Normal Normal Normal

19 00111000 A/1&2 B/3&4 Normal Normal Normal

20 00111001 A/1&2 C/3&4 Normal Normal Normal

21 00111010 A/1&2 D/3&4 Normal Normal Normal

22 00111011 B/1&2 B/3&4 Normal Normal Normal

23 00111100 B/1&2 C/3&4 Normal Normal Normal

24 00111101 B/1&2 D/3&4 Normal Normal Normal

25 00111110 C/1&2 C/3&4 Normal Normal Normal

26 00111111 C/1&2 D/3&4 Normal Normal Normal

27 01000000 D/1&2 D/3&4 Normal Normal Normal

* PB7…PB11 → Push button number * Normal → Normal momentary contact * A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)


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46 01010011 Normal Normal Normal Normal A/1&2

47 01010100 Normal Normal Normal Normal B/1&2

48 01010101 Normal Normal Normal Normal C/1&2

49 01010110 Normal Normal Normal Normal D/1&2














63 01100100 Normal Normal Normal Normal D/1&2



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4.1.3.3 Inline Push Button Configuration (Transmitter Toggle)

The push button arrangement for inline push button setup starts from top to bottom and then from the right column to the left column (refer to Fig. 10 below). To set the inline push button configuration, please refer to JP4 and JP5 jumpers setting on page 36. With inline push button configurations, PB1 & PB2 still corresponds to output relay K1~K4, PB3 & PB4 corresponds to relay K5~K8, etc…

(Fig. 10)



65 00000101 Normal Normal Normal LED 4 Normal

66 00010100 Normal Normal LED 3 LED 4 Normal

67 00010101 Normal LED 2 LED 3 LED 4 Normal

68 00010110 LED 1 LED 2 LED 3 LED 4 Normal




72 00011001 Normal LED 1 LED 2 LED 3 LED 4





* PB7…PB11 → Push button number * Normal → Normal momentary contact * LED 1…LED 4 → Transmitter toggled with designated LED Display


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4.1.3.4 Inline Push Button Configuration (A/B Selector) There are four (4) different types of A/B selector sequences available on the Flex system. Choose the one that is most suitable for your application. Type-A selector sequence : A+B → A → B → A+B … Type-B selector sequence : Off → A → B → Off → A → B … Type-C selector sequence : A → B → A+B → A → B → A+B … Type-D selector sequence : Off → A → B → A+B → Off → A → B → A+B …

DIP PB9 PB10 PB11

77 01110011 A/1&2 Normal Normal

78 01110100 B/1&2 Normal Normal

79 01110101 C/1&2 Normal Normal

80 01110110 D/1&2 Normal Normal

81 00110011 Normal A/3&4 Normal

82 00110100 Normal B/3&4 Normal

83 00110101 Normal C/3&4 Normal

84 00110110 Normal D/3&4 Normal

85 01110111 A/1&2 A/3&4 Normal

86 01111000 A/1&2 B/3&4 Normal

87 01111001 A/1&2 C/3&4 Normal

88 01111010 A/1&2 D/3&4 Normal

89 01111011 B/1&2 B/3&4 Normal

90 01111100 B/1&2 C/3&4 Normal

91 01111101 B/1&2 D/3&4 Normal

92 01111110 C/1&2 C/3&4 Normal

93 01111111 C/1&2 D/3&4 Normal

94 10000000 D/1&2 D/3&4 Normal



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DIP PB9 PB10 PB11

95 10000001 Normal A/1&2 Normal

96 10000010 Normal B/1&2 Normal

97 10000011 Normal C/1&2 Normal

98 10000100 Normal D/1&2 Normal

99 01000101 Normal Normal A/3&4

100 01000110 Normal Normal B/3&4

101 01000111 Normal Normal C/3&4

102 01001000 Normal Normal D/3&4

103 10000101 Normal A/1&2 A/3&4

104 10000110 Normal A/1&2 B/3&4

105 10000111 Normal A/1&2 C/3&4

106 10001000 Normal A/1&2 D/3&4

107 10001001 Normal B/1&2 B/3&4

108 10001010 Normal B/1&2 C/3&4

109 10001011 Normal B/1&2 D/3&4

110 10001100 Normal C/1&2 C/3&4

111 10001101 Normal C/1&2 D/3&4

112 10001110 Normal D/1&2 D/3&4



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DIP PB9 PB10 PB11





117 01010111 Normal Normal Normal
















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4.1.4 Channel Change via Push Buttons Other than the CHANNEL dip-switch on the encoder board, the transmitter channel can also be changed directly on the push buttons. Please refer to the instructions below on how to change the transmitter channel via push buttons.

a. Press and hold PB1, PB2 and PB3 and rotate the power key to START position at the same time. A series of green and red blinks will appear on the Status LED showing the current channel setting. A green blink represents the tens (+10) and a red blink represents the units (+1).

Examples: 2 green blinks followed by 5 red blinks represents channel 25. 6 red blinks represents channel 06.

b. Select a new channel by pressing PB1 and PB2 on the transmitter. Press PB1 to increment the units (+1) and PB2 to increment the tens (+10).

Examples: Pressing PB2 two times and then PB1 four times will give you channel 24.

Pressing PB1 nine times with give you channel 09.

c. When finished, the newly selected channel will appear on the Status LED via a series of green and red blinks again.

d. Exit the channel programming by turning off the transmitter power.

e. Make sure the receiver channel is set identical to the transmitter. Please refer to page 29 and

page 33 on how to change the receiver channel.

f. Please note that when the CHANNEL dip-switch inside the transmitter is changed, the priority will revert back to the new channel set on the CHANNEL dip-switch.

g. Please note that when channel is set beyond channel 62 via PB1 and PB2 (i.e. channel 63, 68,

88, etc…), the system will recognize it as channel 62.


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4.1.5 Optional 4-Digit Security Code The 4-digit Security Code is an optional feature that can be programmed into the transmitter to allow operation only to those who know the code. If this feature is desired, set up as follows: Prior to rotating the transmitter power key-switch to START position to begin operation, you first enter a 4-digit security code in order to proceed further. When this 4-digit security code is entered correctly, a green light will appear on the Status LED. Please refer to the instruction below on how to program the 4-digit security code.

a. Release E-Stop, press and hold PB1, PB2, PB3 and PB4 (all at once), and then rotate the power key to START position.

b. A constant orange light will appear on the Status LED telling you that you are in the security code programming mode.

c. For newly purchased system with the security code function deactivated (default setting), press

PB1 four times (1111) to activate the security code function. At this time the Status LED on the transmitter will blink orange slowly telling you that the 4 digits entered is correct. Then select your own 4-digit security code by pressing PB1, PB2, PB3 or PB4 on the transmitter (four presses randomly). At this time, fast orange blinks are displayed on the Status LED telling you to reconfirm the 4-digit security code you have just entered. A green light will appear once you have re-entered the same 4-digit security code again (programming completed). If any mistake is made during this process, or if a red light is shown on the Status LED after you have re-entered the security code (incorrect input), or even if you believe you have entered the correct code but the transmitter fails to work properly, then you must reset the transmitter power (by power-cycling the transmitter*) and then repeat steps a, b, and c again.

*NOTE: To power-cycle the transmitter, you must first remove, then reinstall the batteries. Simply turning the power switch off, then on will NOT properly clear the memory. This process must be used for any errors regarding proper transmitter operation (not just for security code settings).

Steps: Press and hold PB1~PB4 and rotate power key to START position → constant orange → press PB1 four times (for new systems) or 4-digit security code → slow orange blinks → enter the new 4-digit security code → fast orange blinks → re-enter the same 4-digit security code again → green light.

d. If you wish to cancel the security code function, then repeat steps a, b, and c and press PB1 four

times as your new security code (security code function disabled).

e. If you do not remember the 4-digit security code, then you must contact your dealer or distributor for further assistance.


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4.1.6 I-CHIP The I-CHIP functions in a way that is very similar to a SIM card inside a mobile phone, which stores system information such as your telephone number, account number, phone book and other settings. The I-CHIP works exactly the same way, as it stores information such as system serial number/ID codes, channel configurations and push button configurations. When replacing a transmitter handset, just take the I-CHIP out of the old transmitter and install it into the new one (refer to Fig. 11 below). For a complete information transfer, make sure both the Channel and Function dip-switches are set to all “1”. If both dip-switches are set to all “1”, then the transmitter will operate according to the push button configurations and channel stored inside the I-CHIP. If both the Channel and the Function dip-switches are set to values other than all “1”, then the transmitter will operate according to the channel and push button configurations set on these two dip-switches, not the ones stored inside the I-CHIP. Every time the settings on these two dip-switches are changed, the new settings will be stored into the I-CHIP automatically. In this case the previous channel and push button configurations stored inside the I-CHIP will be erased and be replaced by the new settings. For safety purposes, the system serial number/ID code stored inside the I-CHIP cannot be changed directly on the transmitter encoder board. Only channels and push button configurations can be changed directly on the encoder board via Channel and Function dip-switches. There are only two ways that you can change transmitter serial number/ID codes: 1) via the I-CHIP programming port located on the decoder module inside the receiver unit (please refer to page 37 on how to program the I-CHIP [serial number/ID code] via receiver unit) or 2) via an external I-CHIP programmer or duplicator unit available from the factory. Please ask your local dealer for assistance if your system requires serial number/ID code adjustments.

(Fig. 11)


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4.2 RECEIVER UNIT

4.2.1 System Channel Settings

(Fig. 12) Even though the Flex system is equipped with an automatic channel scanning receiver, the user can also set the receiver channel manually. Please refer to pages 33 and 44 on how the automatic channel scanning receiver works. Set the receiver channel by adjusting the channel dip-switch located on the receiver module (refer to Fig. 12 above); only the first six (6) positions are used for channel programming (refer to Fig. 13 below). The system channels table located on page 38 illustrates which dip-switch setting corresponds to which channel. Once the receiver channel is altered make sure to change the transmitter channel as well. The channel on both the transmitter and the receiver must be identical in order for system to work. To change the transmitter channel please refer to page 17. Example:

(Fig. 08)

The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38.


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4.2.2 Output Relay Configurations

4.2.2.1 Output Relay Types

1. Three (3) output relays per motion – shared 2nd speed output relay Output relays with Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) share the same output relay.

2. Four (4) output relays per motion – separate 1st and 2nd speed output relays

Output relays with Forward 1st speed (F1), Reverse 1st speed (R1), Forward 2nd speed (F2) and Reverse 2nd speed (R2). Forward and Reverse 2nd speed with separate output relays.

4.2.2.2 Output Relay Actions at 2nd Speed

1. 3-output relays configuration with Closed/Closed contact at 2nd speed At 2nd speed, both 1st speed (F1 or R1) and 2nd speed (F/R2) output relays are closed (refer to page 34 on how to set to this function).


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2. 4-output relays configuration with Opened/Closed contact at 2nd speed

At 2nd speed, only the 2nd speed (F2 or R2) output relay is closed (refer to page 34 on how to set to this function).

3. 4-output relays configuration with Closed/Closed contact at 2nd speed At 2nd speed, both 1st speed (F1 or R1) and 2nd speed (F2 or R2) output relays are closed (refer to page 34 on how to set to this function).

4.2.2.3 ON/OFF Push Button Function The user can set any of the two adjacent push buttons on the transmitter to behave like a mechanical ON & OFF rocker switch (refer to page 34 on how to set to this function). When “On” output relay is closed (“On” push button pressed), the “Off” output relay will open automatically, or vice versa.

4.2.2.4 START/AUX Function After initiating the START function the Start position will become an auxiliary function with momentary contact. For an auxiliary applications such as horns or buzzers, please connect it to the FUNC output relay (wire #6) located inside the receiver unit.


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4.2.2.5 Magnet ON/OFF Push Button Function The user can set any of the two adjacent push buttons on the transmitter to control a magnet. To activate the magnet just press the push button with the Magnet symbol. To deactivate the magnet, for safety purposes, you must first press and hold the Magnet push button and then press the OFF push button. Pressing the OFF push button by itself cannot deactivate the magnet (refer to page 34 on how to set to this function).

4.2.2.6 Brake Function When the transmitter push button is released from 2nd speed up to 1st speed, both 1st and 2nd speed output relays will open for up to 1.0 second and then with 1st speed output relay closed thereafter (refer to page 34 on how to set to this function).

4.2.2.7 Momentary Contact When the push button is released the output relay that corresponds to that push button will open (refer to page 35 on how to set to this function). This type of contact is usually applied to external applications such as horns or buzzers.

4.2.2.8 Toggled Contact When the push button is released the output relay that corresponds to that push button will remained closed (maintained contact) until next time the user presses the same push button again (refer to page 35 on how to set to this function). This type of contact is usually applied to external applications such as lights.

4.2.2.9 3rd Speed Push Button Function This function allows the crane to travel an additional step beyond 2nd speed. For example, if the operator is pressing the “UP” push button down to 2nd speed, pressing the 3rd speed push button (with “UP” push button still held at 2nd speed) will toggle between 2nd speed and 3rd speed (refer to page 35 on how to set to this function).

4.2.2.10 Auxiliary STOP Push Button Function The auxiliary STOP function acts as a 2nd emergency stop button. Other than by emergency stop button and transmitter power key switch, the receiver MAIN is also deactivated when this auxiliary stop push button is pressed (refer to page 35 on how to set to this function).

4.2.2.11 Pitch & Catch Function This function allows two operators to control one crane from opposite ends of a cross or long travel (refer to page 35 on how to set to this function). When set to “Pitch & Catch,” make sure the 2nd transmitter is set to the next upper channel (channel X*+1). For example, if the system is preset at “Ch.01” then the channel of the 2nd transmitter should be set to “Ch.02”. Furthermore, the dip-switch position #7 and #8 on the receiving module should be set to “10”, as this will allow the receiver to scan only Ch.01 and Ch.02 (please refer to the illustration below). On the other hand, since there are only 62 available channels on the Flex system, the system preset at channel 62 is ineffective because the 2nd transmitter cannot be set to Ch.63. If your system is preset at Ch.62 make sure to change it to another channel.


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41 32 65 87

41 32 65 87

42 31 7 85 6

41 2 3 65 7 8

4.2.3 Receiver Auto-Scanning Settings Receiver Channel Dip-switch

↓

(1) → Scanning all 62 channels (manufacture preset) For standard operation

(2) → Single fixed channel (channel X*) Auto scanning function disabled

(3) → Scanning 2 channels only (channel X*, channel X*+1)

For Pitch & Catch, Tandem, and Random Access operation with 2 receivers

(4) → Scanning 3 channels only (channel X*, channel X*+1,

channel X*+2) For Random Access operation with 3 receivers

* Channel X → Channel set on the receiving module

Example: If the first 6 dip-switch positions on the receiving module is set to Ch.01

(“000000” or “000001”), when set to 2-channel scanning (type-3 above),

then the receiver will only scan Ch.01 and Ch.02.


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4.2.4 Dip-Switch Settings

4.2.4.1 Interlocked Functions Interlocked means the two adjacent push buttons cannot be activated simultaneously as they will cancel each other out. Interlocked settings are usually applied to a crane’s forward and reverse motions. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (refer to Fig. 14 & 15 below). Only the first seven (7) dip-switch positions are used (counting from left to right); the 8th dip-switch position (far right) is not used.

(Fig. 14) (Fig. 15)

▇ Manufacture preset

Dip Settings

Function Descriptions # of Relays

Used

0000000 Normal (single speed only, F2 & R2 relays not used). 2

0000001 Closed/Closed Relay Action at 2nd Speed (separate 2nd speed

relay). 4

0000010 Closed/Closed Relay Action at 2nd Speed (shared 2nd speed

relay). 3

0000011 Opened/Closed Relay Action at 2nd Speed (separate 2nd speed

relay). 4

0000110 On (right button) & Off (left button). 2

0001000 On & Off affected by the E-stop command. When E-stop

command is initiated, the Off relay is activated. 2

0001001 On + Start / Off + Start -- Prior to pressing the button you must

first rotate and hold the power key switch at START position to

activate On or Off relays.

2

0001010 FWD/REV toggled (latched). 2

0001011 FWD/REV toggled (latched) and affected by the E-stop

command. 2

0000111 Safety Magnet On & Off. 2

0100001 Closed/Closed + Brake. 4

0100010 Closed/Closed Relay Action + Brake. 3

0100011 Opened/Closed Relay Action + Brake. 4


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4.2.4.2 Non-Interlocked Functions Contrary to interlocked settings, non-interlocked settings allow the two adjacent push buttons be used simultaneously. Non-interlocked settings are usually applied to a crane’s auxiliary functions such as lights, horns, 3rd speed, auxiliary stops and Pitch & Catch. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (left & right push buttons).

Function Code

Dip Position Setting

#1

Dip Position Setting#2 - #4 (left button)

& #5 - #7 (right button)

Function Description

A 1 000 Normal (momentary) contact.

B 1 001 Toggled (latching) contact.

C 1 010 Acceleration (3rd speed).

D 1 100

Normal + Start function. For added safety,

you must first rotate and hold the power key

switch at “START” position and then press

the intended push button at the same

time to activate the output relay.

E 1 110 Pitch & Catch

F 1 111 Auxiliary Stop.

Example #1: Left button (set to function code A) / right button (set to function code A) → 1 000 000 Example #2: Left button (set to function code B) / right button (set to function code B) → 1 001 001 Example #3: Left button (set to function code A) / right button (set to function code C) → 1 000 010 Example #4: Left button (set to function code F) / right button (set to function code A) → 1 110 000 NOTE: When set to Pitch & Catch function, make sure the 2nd transmitter is set to the next upper channel. For example, if the system is preset at Ch.01, then the 2nd transmitter should be set to Ch.02. Furthermore, you must also set the dip-switch on the receiving module (position #7 & #8) to “10” position (2-channel scanning), please refer to page 33.


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4.2.5 Jumper Settings Jumper settings are applied to functions such as mainline-disconnect time, Start function, transmitter push button layout, system information (serial number/ID code) programming and system testing. The jumpers #1- #7 are located on the decoder module above the four (4) dip-switches (refer to Fig.16 below).

(Fig. 16)

▇ Manufacture preset

Jumper Settings Function

JP3 (Blank)

After 1 or 3 minutes of transmitter inactivity (MAIN deactivated), press any push button on the transmitter to reactivate the receiver MAIN.

JP3 (Inserted)

After 1 or 3 minutes of transmitter inactivity (MAIN deactivated), rotate the transmitter power key-switch to “START” position to reactivate the receiver

MAIN.

JP4 (Blank)

JP5 (Blank)

Standard right-to-left push button configuration for all models.

JP4 (Inserted)

JP5 (Blank)

In-line push button configuration (top to bottom) for Flex 8ES/EX.

JP4 (Blank)

JP5 (Inserted)


JP4 (Inserted)

JP5 (Inserted)


JP6 (Blank)

Program system serial number/ID code and channel from decoder module to I-CHIP.

JP6 (Inserted)

Program system serial number/ID code and channel from I-CHIP to decoder module.

JP7 (Inserted)

For system test only, receiver MAIN disabled.


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4.2.6 I-CHIP Programming Port

(Fig. 17) The I-CHIP programming port located on the decoder module (refer to Fig. 17 above) inside the receiver is designed for the purpose of transferring system serial number/ID code either from the I-CHIP to the receiver or vice versa. If you wish to transfer system information from the receiver to the I-CHIP, just insert the I-CHIP onto the programming port (JP6 jumper not inserted), wait until the Status LED on the decoder module turns a constant green (within 2 seconds), and then take the I-CHIP out of the programming port (programming completed). At this time the I-CHIP should also possess the same serial number/ID code as the receiver. If the Status LED on the decoder module displayed a constant red light after inserting the I-CHIP (programming failed), then you must reinsert the I-CHIP one more time. On the other hand, if you wish to transfer system information from the I-CHIP to the receiver, then you must first insert JP6 jumper prior to inserting the I-CHIP, then wait for the green light to appear on the Status LED. At this time the receiver should also possess the same system information as the I-CHIP. Please note that the receiver unit must be powered in order to proceed with the programming.

4.2.7 Voltage Settings Always check the voltage setting is correct for your application prior to installation (refer to Fig. 18 below). Position 1 → 110-120VAC Position 2 → 220-240VAC or 24VAC* Position 3 → 380-400VAC or 42VAC* Position 4 → 410-460VAC or 48VAC* or 12-24VDC** * For system with 24/42/48VAC power supply. ** For system with 12 - 24VDC power supply. (Fig. 18)

F9 and F10 power fuse ratings: FUSE # 110 -

120VAC 220 -

240VAC 380 -

400VAC 410 -

460VAC 24VAC 42 & 48VAC 12 - 24VDC

F9 1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)

F10 1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)

* Output relay fuse → 5.0A (clear)


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5. SYSTEM CHANNELS TABLE

Channel Frequency Dip-switch Setting Channel Frequency Dip-switch

Setting

01 433.000MHZ 000000 32 433.775MHZ 100000 01 433.000MHZ 000001 33 433.800MHZ 100001 02 433.025MHZ 000010 34 433.825MHZ 100010 03 433.050MHZ 000011 35 433.850MHZ 100011 04 433.075MHZ 000100 36 433.875MHZ 100100 05 433.100MHZ 000101 37 433.900MHZ 100101 06 433.125MHZ 000110 38 433.925MHZ 100110 07 433.150MHZ 000111 39 433.950MHZ 100111 08 433.175MHZ 001000 40 433.975MHZ 101000 09 433.200MHZ 001001 41 434.000MHZ 101001 10 433.225MHZ 001010 42 434.025MHZ 101010 11 433.250MHZ 001011 43 434.050MHZ 101011 12 433.275MHZ 001100 44 434.075MHZ 101100 13 433.300MHZ 001101 45 434.100MHZ 101101 14 433.325MHZ 001110 46 434.125MHZ 101110 15 433.350MHZ 001111 47 434.150MHZ 101111 16 433.375MHZ 010000 48 434.175MHZ 110000 17 433.400MHZ 010001 49 434.200MHZ 110001 18 433.425MHZ 010010 50 434.225MHZ 110010 19 433.450MHZ 010011 51 434.250MHZ 110011 20 433.475MHZ 010100 52 434.275MHZ 110100 21 433.500MHZ 010101 53 434.300MHZ 110101 22 433.525MHZ 010110 54 434.325MHZ 110110 23 433.550MHZ 010111 55 434.350MHZ 110111 24 433.575MHZ 011000 56 434.375MHZ 111000 25 433.600MHZ 011001 57 434.400MHZ 111001 26 433.625MHZ 011010 58 434.425MHZ 111010 27 433.650MHZ 011011 59 434.450MHZ 111011 28 433.675MHZ 011100 60 434.475MHZ 111100 29 433.700MHZ 011101 61 434.500MHZ 111101 30 433.725MHZ 011110 62 434.525MHZ 111110 31 433.750MHZ 011111 I-CHIP 111111*

* When set to all “1” the priority goes to the channel assigned inside the I-CHIP.


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6. RECEIVER INSTALLATION 6.1 OUTPUT RELAY CONTACT DIAGRAM

For the 3-relay (shared 2nd speed) and 4-relay (separate 2nd speed) configuration please refer to page 30.

For the 4-relay closed/closed and 4-relay opened/closed relay configuration please refer to pages

30 and 31.

For different voltage settings please refer to page 37.

For F9 and F10 power fuse ratings please refer to page 37.

For 12-24VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+). Wire #2 is for GROUND.


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6.2 PRE-INSTALLATION PRECAUTIONS 1. Make sure the transmitter and the receiver have identical serial number/ID codes and channels.

2. Make sure the receiver is not set to the same channel as any other systems in use in the

surrounding area.

3. Make sure that the crane or equipment is working properly prior to installation.

4. Make sure the power source to the receiver is set correctly.

5. Switch off the main power source to the crane or equipment prior to installation.

6.3 STEP-BY-STEP INSTALLATION

(Fig. 19)

1. For best reception the location of the receiver should be visible to the operator at all time.

2. The location selected should not be exposed to high levels of electric noise. Mounting the receiver next to an unshielded variable frequency drive may cause minor interference. Always locate the receiver as far away from variable frequency drives as possible.


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432 mm

ControlPanel

3. Ensure the selected location has adequate space to accommodate the receiver (refer to Fig. 19 on page 40). If an external antenna is used, always locate the receiver where the antenna is free from any obstacles from all directions to avoid the possibility of antenna damage (refer to diagram at right).

4. When installing an external antenna you must connect the SMA jack

located inside the receiver and make sure to set the jumper to “EXT” position (refer to diagram below).

5. For better reception, make sure the receiver is in an upright position.

6. Drill two holes (10mm in diameter) on the control panel or location where the receiver is to be

installed (refer to Fig. 19 on page 40).

7. Make sure the two bolts are tightened after installation.

8. For system wiring please refer to page 39.

6.4 SYSTEM TESTING 1. Turn on the power source to the receiver and test the MAIN relay output by pressing the red

emergency stop button and observe that it properly opens and closes the mainline disconnect contactor.

2. Test the operation of each function to ensure it corresponds to the transmitter direction labels or

the pendant it is replacing.

3. Test the limit switches (if any) to see if they are working properly.

4. If your new remote control is replacing an existing pendant, make sure it is completely disconnected and placed in a safe location to prevent unwanted control commands.


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7. Operating Procedure 7.1 TRANSMITTER OPERATION

7.1.1 General Operating Procedure a. Reset the red emergency stop button located on the top left hand side of the transmitter handset

by rotating it either clockwise or counter clockwise. The red button will pop up.

b. Turn on the transmitter power by inserting the black-colored key into the power key slot (located

on the top right hand side of the transmitter handset) and rotate it clockwise to the “On” position.

c. After turning on the transmitter power, check the Status LED on the transmitter handset for any sign of system irregularities (refer to “Status Light Indicators & Warnings” on page 46). If the system is normal, the Status LED will light up green for two (2) seconds.

d. If there are no signs of any system irregularities, then rotate the power key-switch further to

START position for up to 1.0 second to activate all transmitter push button functions and as well as the receiver MAIN. Then press any push button on the transmitter to begin operation. Pressing any push button prior to initiating the START command will result in no signal transmitted (blinking orange light).


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e. In case of an emergency, pressing down the red emergency stop button will immediately

disconnect the receiver MAIN and as well as the transmitter power. To resume operation, rotate the red button clockwise or counter clockwise, it will pop up. Then rotate the power key-switch to START position for up to 1.0 second to activate all transmitter push button functions and the receiver MAIN. Please note that every time when you turn the transmitter power off and back on again, or after resetting the emergency stop button, all push button functions will be locked to avoid any unintentional controls. For safety, initiating the START command after turning on the transmitter power or after resetting the emergency stop button is strictly required.

f. After 1 minute of inactivity (push button not pressed) the receiver MAIN will be disconnected

temporarily. To resume operation, just press any push button on the transmitter to resume operation (depending on JP3 setting on page 36). If this 1-minute inactivity time is not sufficient for your application, you can also extend this inactivity time from 1 minute up to 3 minutes (refer to Continuous Transmitting Time Adjustment on page 18). The receiver MAIN will also be disconnected temporarily when the receiver encounters strong radio interference or when the operator is controlling the crane or equipment beyond the transmitting range.

g. To turn off the transmitter power just rotate the power key to “Off” position, it will disconnect the transmitter power and the receiver MAIN altogether.

7.1.2 Rotary Select A/B Operating Procedure This changeover function is designed specifically for crane systems with dual hoists and/or trolleys. Switch between the main and auxiliary hoists simply by rotating the selector switch to either A, B, or A+B. For system wiring please refer to page 39.

7.1.3 Push Button Select A/B Operating Procedure Pressing the “Select A/B” push button will toggle between output relay A, B and A+B respectively. There are four different types of Select A/B sequences available; please refer to page 20 for instructions on how to set Select A/B functions.


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7.1.4 3rd Speed Push Button Operating Procedure When a push button is held at 2nd speed, pressing the 3rd Speed push button one time will activate the 3rd speed output relay (toggled). If the operator wants 2nd speed again, just press the 3rd Speed push button one more time.

7.1.5 Pitch & Catch Operating Procedure To release control of the crane, press the “Pitch” push button. To take over control of the crane, rotate the power key switch to the “Catch” position for up to 2 seconds. The second operator cannot take control of the crane unless the first operator presses the “Pitch” push button (2.0 seconds). If the operator unintentionally presses the “Pitch” push button during operation, just rotate the power key to the “Catch” position for up to 2 seconds to regain control.

7.1.6 Automatic Channel Scanning Operating Procedure After changing the transmitter channel (refer to page 17), turn on the transmitter power, rotate the power key switch to the “Start” position, and hold it there for up to 1 minute. Within this 1-minute period the receiver will search (channel 01 ~ channel 62) and lock onto the newly selected transmitter channel automatically. Please note that in order for the receiver to switch to auto-scanning mode, you must first deactivate the receiver MAIN by shutting off the transmitter power or press down the emergency stop button before changing the transmitter channel. Please refer to page 33 if you do not want the receiver to auto-scan all 62 channels.


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7.1.7 Changing Transmitter Batteries Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to Fig. 20 below). During battery installations make sure that the blue ribbon is centered between the two batteries. After changing the batteries make sure that all screws are tightened to avoid water, moisture, dirt, grease, or other liquid penetration.

(Fig. 20)


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7.2 STATUS LIGHT INDICATORS & WARNINGS

7.2.1 Transmitter STATUS Light Indication

Type Display Type Indication

1 Constant red

Voltage below 1.9V at initial power on -

transmitter power and receiver MAIN shuts off.

Voltage below 1.8V during operation -

transmitter power and receiver MAIN shuts off.

2 1 red blink followed by a 2-

second pause

Voltage goes below 1.85V during operation -

change batteries immediately.

3 2 red blinks followed by a 2-

second pause

The push button is defective after turning on the

transmitter power.

4 No light displayed

When a defective push button condition occurs

(2 red blinks, type 3 above), find out which push

button is defective by pressing all the push

buttons on the transmitter one at a time. If the

push button is in good working order, the LED

will not light up when pressed. If the push

button is defective the LED will continue to

display 2 red blinks when pressed.


second pause EEPROM error.


second pause

Transmitting error; system cannot lock on

to the designated channel.

7 Constant green for up to 2

seconds Transmitter power on with no faults detected

8 Blinking green Transmission in progress

9 Blinking orange Transmitter push button functions locked.


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7.2.2 Receiver STATUS Light Indication

Type Display Type Indication

1 Fast green blinks Decoding in process

2 Slow green blinks Decoding on standby

3 Two red blinks Receiver MAIN is jammed or defective

4 Fast red blinks Incorrect transmitter serial number/ID code

5 Constant red Receiver under-voltage, LV output relay

activated

6 No light displayed Decoding microprocessor is defective

7.2.3 Receiver SQ Light Indication

Type Display Type (Red) Indication

1 Fast blinks Transmission received

2 Completely off No transmission

3 Blinks intermittently Other radio interference

7.2.4 Receiver POWER Light Indication


1 On Power to receiver

2 Off No power to receiver

7.2.5 Receiver COM Light Indication


1 On Power to relay board

2 Off No power to relay board


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7.3 TROUBLESHOOTING TIPS

Problems Possible Reasons Suggestions

No response when transmitter push button is pressed

(Improper startup & settings)

Transmitter low battery power Check the transmitter battery level.

Emergency stop button

activated prior to startup

Prior to turning on the transmitter power switch

make sure that the red emergency stop button

is elevated.

Transmitter push button functions

locked

Initiate the Start command by rotating the power

key-switch to START position.

Incorrect system RF channel

Check and make sure that the transmitter

handset and receiver unit both have the same

channel.

Incorrect system serial

number/ID code

Check and make sure that the transmitter

handset and receiver unit both have the same

serial number/ID code.

System out of range

Make sure that the startup procedure is

initiated within 100 meters (300 feet) from the

receiver location.

No response when transmitter push button is pressed

(Damaged hardware)

Defective transmitting and

receiving module

Check the SQ display on the face of the

receiver unit. If it does not light up when the

push button is pressed then either the

transmitting or receiving module is defective.

First replace the transmitting module. If SQ

display is still not lit when the push button is

pressed then go ahead and replace the

receiving module.

Defective encoder

board or decoder module

If still no response, then replace the transmitter

encoder board. If still

doesn’t work then the decoder module

is defective.

No AC power to the receiver

Incorrect input voltage Make sure the source voltage is set correctly.

Blown fuse Check for any blown fuse.

Incorrect wiring Check input voltage connection.

Outputs do not correspond to

transmitter Incorrect output connection

Check the system wiring again. Please refer to

the output contact diagram inside this manual

or on the receiver cover.


of 49

8. SYSTEM SPECIFICATIONS Frequency Range : 433 - 434 MHz Frequency Deviation : 12.5 KHz Number of Channels : 62 channels Modulation : Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC Parity Check and Hamming Code. Encoder & Decoder : Microprocessor-controlled Transmitting Range : >100 Meters / 300 Feet Frequency Control : Synthesized PLL (Phase Lock Loop) Receiver Type : Frequency Auto Scanning Receiver Sensitivity : -116dBm Antenna Impedance : 50 ohms Responding Time : 60 Milliseconds (average) Transmitting Power : 0.3mW Enclosure Type : NEMA-4X Enclosure Rating : IP-66 Output Contact Rating : 250V @ 8 Amps Transmitter Operating Voltage : DC 3.0V Receiver Power Consumption : 11.0 VA Receiver Supply Voltage : Voltage Setting Min ~ Max 24VAC (22 ~ 26VAC) 42VAC (38 ~ 46VAC) 48VAC (43 ~ 53VAC) 110VAC (104 ~ 126VAC) 220VAC (207 ~ 253VAC) 380VAC (351 ~ 429VAC) 410VAC (400 ~ 480VAC) 12/24VDC (9 ~ 36VDC) Operating Temperature : -25°C -- 75°C / -13°F -- 167°F Transmitter Dimension : 230mm (L) x 69mm (W) x 35mm (H) Receiver Dimension : 363mm (L) x 228mm (W) x 70mm (H) Transmitter Weight : 296g / 10.4oz Receiver Weight : 2.5kg / 5.5lb

Radio Control Equipment Instruction Manual - Magnetek/media/Manuals/Material Handling...

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Transcript of Radio Control Equipment Instruction Manual - Magnetek/media/Manuals/Material Handling...